Nordson ColorMax 2 Reference guide

ColorMaxr2 Powder Coating

System with EncorerFeed Center

Customer Product Manual

Part 1605397-04

Issued 02/20

NORDSON CORPORATION AMHERST, OHIO USA

For parts and technical support, call the Industrial Coating

Systems Customer Support Center at (800) 433-9319 or

contact your local Nordson representative.

This document is subject to change without notice.

Check http://emanuals.nordson.com for the latest version.

Part 1605397-04 2015 Nordson Corporation

Nordson Corporation welcomes requests for information, comments, and

inquiries about its products. General information about Nordson can be

found on the Internet using the following address:

http://www.nordson.com.

Address all correspondence to:

Nordson Corporation

Attn: Customer Service

555 Jackson Street

Amherst, OH 44001

Notice

This is a Nordson Corporation publication which is protected by copyright.

Original copyright date 2014. No part of this document may be

photocopied, reproduced, or translated to another language without the

prior written consent of Nordson Corporation. The information contained

in this publication is subject to change without notice.

Trademarks

ColorMax, iControl, Nordson, and the Nordson logo are registered

trademarks of Nordson Corporation.

AeroDeck and AeroWash are trademarks of Nordson Corporation.

Change Record i

Part 1605397-04

2015 Nordson Corporation

Change Record

Revision Date Change

02 04/15 Replaced part number 1058969 with part number 1606403. Changed

screen 8 from 20.00 minutes to 10.00 minutes.

03 05/15 Added slidegate assembly parts.

04 10/15 Replaced part number 1008803 with part number 1607911. Added part

number 176299 (12-valve pilot solenoid).

Change Record

Part 1605397-04 2015 Nordson Corporation

Table of Contents iii

Part 1605397-04

2015 Nordson Corporation

Table of Contents

Safety 1-1..................................................

Introduction 1-1.............................................

Qualified Personnel 1-1......................................

Intended Use 1-1............................................

Regulations and Approvals 1-1................................

Personal Safety 1-2.........................................

Fire Safety 1-2..............................................

Grounding 1-3..............................................

Action in the Event of a Malfunction 1-4........................

Disposal 1-4................................................

Description 2-1.............................................

Introduction 2-1.............................................

System Components 2-2....................................

Booth 2-4...............................................

Reclaim System 2-6......................................

Feed Center 2-8..........................................

Automatic Gun Movers/Gun Blow-Off 2-10....................

Afterfilter 2-11.............................................

Afterfilter Operation 2-11.................................

Control Panels 2-13...........................................

Encore Venturi Feed Center Control Panel 2-13................

Main Electrical Control Panel 2-15............................

Typical System Options 2-16...................................

Roll-On/Roll-Off System 2-16................................

Operation 3-1..............................................

Introduction 3-1.............................................

Typical Operating Settings 3-2................................

Operating Air Pressures 3-2................................

Timer Board Settings 3-2...................................

Booth Control Functions 3-3...............................

Changing Function Values 3-6...........................

Startup 3-7.................................................

Ancillary Equipment Clean Function 3-9.....................

Color Change Procedures 3-9..............................

Powder Level Sensor Operation 3-10........................

Booth Moving 3-10...........................................

Shutdown 3-11...............................................

Table of Contents

Part 1605397-04 2015 Nordson Corporation

Maintenance 4-1...........................................

Initial Canopy Conditioning 4-1...............................

Daily Maintenance 4-2.......................................

System Cleaning 4-2......................................

Daily Equipment Maintenance 4-2...........................

Weekly Maintenance 4-4.....................................

Monthly Maintenance 4-4.....................................

Booth Canopy Conditioning 4-5...............................

Cyclone Cleaning 4-6.......................................

HDLV Transfer Pump and Transfer Pan Maintenance 4-7........

Transfer Pan Cleaning 4-8.................................

Disassembly 4-8.......................................

Cleaning 4-8..........................................

Assembly 4-8..........................................

Emptying the Afterfilter Waste Hoppers 4-10.....................

Maintenance Check List 4-11..................................

Troubleshooting 5-1........................................

Common Problems 5-1......................................

Reversing Motor Direction 5-6.................................

Repair 6-1.................................................

Introduction 6-1.............................................

Cartridge Filter Replacement 6-1..............................

Filter Removal 6-1........................................

Filter Installation 6-2.......................................

Seasoning the Cartridge Filters 6-4..........................

Final Filter Replacement 6-5.................................

Pulse Valve Replacement 6-6................................

Preparation 6-6...........................................

Parts 7-1...................................................

Introduction 7-1.............................................

Afterfilter Parts 7-2..........................................

Gun Blow-Off Parts 7-4......................................

Miscellaneous Parts 7-4......................................

System Diagram 8-1........................................

Safety 1-1

Part 1605397-04

2015 Nordson Corporation

Section 1

Safety

Introduction

Read and follow these safety instructions. Task- and equipment-specific

warnings, cautions, and instructions are included in equipment

documentation where appropriate.

Make sure all equipment documentation, including these instructions, is

accessible to all persons operating or servicing equipment.

Qualified Personnel

Equipment owners are responsible for making sure that Nordson equipment

is installed, operated, and serviced by qualified personnel. Qualified

personnel are those employees or contractors who are trained to safely

perform their assigned tasks. They are familiar with all relevant safety rules

and regulations and are physically capable of performing their assigned

tasks.

Intended Use

Use of Nordson equipment in ways other than those described in the

documentation supplied with the equipment may result in injury to persons

or damage to property.

Some examples of unintended use of equipment include

using incompatible materials

making unauthorized modifications

removing or bypassing safety guards or interlocks

using incompatible or damaged parts

using unapproved auxiliary equipment

operating equipment in excess of maximum ratings

Regulations and Approvals

Make sure all equipment is rated and approved for the environment in which

it is used. Any approvals obtained for Nordson equipment will be voided if

instructions for installation, operation, and service are not followed.

Safety

1-2

Part 1605397-04 2015 Nordson Corporation

All phases of equipment installation must comply with all federal, state, and

local codes.

Personal Safety

To prevent injury follow these instructions.

Do not operate or service equipment unless you are qualified.

Do not operate equipment unless safety guards, doors, or covers are

intact and automatic interlocks are operating properly. Do not bypass or

disarm any safety devices.

Keep clear of moving equipment. Before adjusting or servicing any

moving equipment, shut off the power supply and wait until the

equipment comes to a complete stop. Lock out power and secure the

equipment to prevent unexpected movement.

Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or

servicing pressurized systems or components. Disconnect, lock out,

and tag switches before servicing electrical equipment.

Obtain and read Material Safety Data Sheets (MSDS) for all materials

used. Follow the manufacturer’s instructions for safe handling and use

of materials, and use recommended personal protection devices.

To prevent injury, be aware of less-obvious dangers in the workplace

that often cannot be completely eliminated, such as hot surfaces, sharp

edges, energized electrical circuits, and moving parts that cannot be

enclosed or otherwise guarded for practical reasons.

Fire Safety

To avoid a fire or explosion, follow these instructions.

Do not smoke, weld, grind, or use open flames where flammable

materials are being used or stored.

Provide adequate ventilation to prevent dangerous concentrations of

volatile materials or vapors. Refer to local codes or your material MSDS

for guidance.

Do not disconnect live electrical circuits while working with flammable

materials. Shut off power at a disconnect switch first to prevent

sparking.

Safety 1-3

Part 1605397-04

2015 Nordson Corporation

Know where emergency stop buttons, shutoff valves, and fire

extinguishers are located. If a fire starts in a spray booth, immediately

shut off the spray system and exhaust fans.

Clean, maintain, test, and repair equipment according to the instructions

in your equipment documentation.

Use only replacement parts that are designed for use with original

equipment. Contact your Nordson representative for parts information

and advice.

Grounding

WARNING: Operating faulty electrostatic equipment is hazardous and can

cause electrocution, fire, or explosion. Make resistance checks part of your

periodic maintenance program. If you receive even a slight electrical shock

or notice static sparking or arcing, shut down all electrical or electrostatic

equipment immediately. Do not restart the equipment until the problem has

been identified and corrected.

All work conducted inside the spray booth or within 1 m (3 ft) of booth

openings is considered within a Class 2, Division 1 or 2 Hazardous location

and must comply with NFPA 33, NFPA 70 (NEC articles 500, 502, and 516),

and NFPA 77, latest conditions.

All electrically conductive objects in the spray areas shall be electrically

connected to ground with a resistance of not more than 1 megohm as

measured with an instrument that applies at least 500 volts to the circuit

being evaluated.

Equipment to be grounded includes, but is not limited to, the floor of the

spray area, operator platforms, hoppers, photoeye supports, and

blow-off nozzles. Personnel working in the spray area must be

grounded.

There is a possible ignition potential from the charged human body.

Personnel standing on a painted surface, such as an operator platform,

or wearing non-conductive shoes, are not grounded. Personnel must

wear shoes with conductive soles or use a ground strap to maintain a

connection to ground when working with or around electrostatic

equipment.

Operators must maintain skin-to-handle contact between their hand and

the gun handle to prevent shocks while operating manual electrostatic

spray guns. If gloves must be worn, cut away the palm or fingers, wear

electrically conductive gloves, or wear a grounding strap connected to

the gun handle or other true earth ground.

Shut off electrostatic power supplies and ground gun electrodes before

making adjustments or cleaning powder spray guns.

Connect all disconnected equipment, ground cables, and wires after

servicing equipment.

Safety

1-4

Part 1605397-04 2015 Nordson Corporation

Action in the Event of a Malfunction

If a system or any equipment in a system malfunctions, shut off the system

immediately and perform the following steps:

Disconnect and lock out electrical power. Close pneumatic shutoff

valves and relieve pressures.

Identify the reason for the malfunction and correct it before restarting the

equipment.

Disposal

Dispose of equipment and materials used in operation and servicing

according to local codes.

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